5S

THE SECRET TO
SUCCESS
 WHAT PROBLEMS ARE COMMONLY
ENCOUNTERED AT WORKPLACE

HIGH ABSENTEEISM
HIGH EMPLOYEE TURNOVER
DEMOTIVATED EMPLOYEES
DISORDERED/ CLUTTERED ENVIRONMENT
MISTAKES/ERRORS
THE SOLUTION TO ALL
PROBLEMS IS

5S
 5S
HOUSEKEEPING TECHNIQUE

PRODUCTIVITY AND SAFETY

ENHANCEMENT TECHNIQUE
 IDEA BEHIND 5S

IN ORDER TO ACHIEVE HIGH LEVELS

OF QUALITY, SAFETY AND
PRODUCTIVITY, WORKERS MUST
HAVE A CLEAN AND PLEASANT
WORKING ENVIRONMENT
 WHAT IS 5S?

Developed by the Japanese

Housekeeping system
Helps create a better working
environment and a consistently high
quality process based system
 THE 5S PRINCIPLES

SEIRI – Organisation/Sort out

SEITON – Orderliness/Systemize
SEISO – The Cleaning/Shining
SEIKETSU – STANDARDIZE
SHITSUKE - Sustain/Discipline
 DISCOVERY OF 5S
Thirty years ago researchers started
studying the secret of success of Japanese
manufacturing companies

5S turned out to be the most impressive

"secret“

The factories were so well organized that

abnormal situations were easily visible
 DISCOVERY OF 5S
Equipments were so clean and well
maintained that any problem such as
a loose bolt or leaking oil could be
easily seen
This passion of cleanliness and
orderliness became a hallmark of
Japanese organizations
 ADVANTAGES OF 5S
If tools and materials are conveniently
located in uncluttered work areas

Operators spend less time looking for items

This leads to higher workstation efficiency, a

fundamental goal in mass production
 ADVANTAGES OF 5S

A clean and tidy workplace leads to

greater well being and increased
motivation
Company image improves
 ADVANTAGES OF 5S

Health and Safety is ensured

Machine maintenance
Quality
Productivity
Lean Manufacturing
 ADVANTAGES OF 5S
RESULTS IN A PLACE EASIER TO MANAGE

SMOOTH WORKING

 NO OBSTRUCTION

NO DEVIATION, NO PROBLEM

B/C EVERYONE KNOWS WHERE THE THINGS

ARE SUPPOSEDE TO BE
 ADVANTAGES OF 5S

TIME SAVING
QUICK RETRIEVAL
ACCIDENTS & MISTAKES MINIMIZED
INCREASES SPACE
CREATES WORKPLACE OWNERSHIP
 ADVANTAGES OF 5S
FOUNDATION OF ALL QC TOOLS

CONTINUOUS QUALITY IMPROVEMENT

LEAN MANUFACTURING
KINDERGARTEN OF QUALITY TOOLS &
TECHNIQUES
 ADVANTAGES OF 5S
VISUAL MANAGEMENT SYSTEM

VISUAL CONTROL TO SEE THE ABNORMALITIES

SIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING
OF THE CONDITION
(NORMAL / ABNORMAL)
A LOOK AT THE PROCESS REVEALS ITS DIRECTION
(RIGHT/WRONG)
 Lean Production

The latest evolution of JIT

Based on Toyota Production System.
Waste elimination
Widely used in automotive
manufacturing & other repetitive
manufacturing
It’s the elimination of waste Everywhere –
while adding customer value…

It’s a mindset & commitment to

achieve a totally waste-free
operation that’s focused on your
customer’s success… achieved
by simplifying and continuously
improving all processes
 From the operations perspective
Lean production cuts costs & inventories
rapidly to free cash, which is critical

It also supports growth by improving

productivity & quality, reducing lead times,
and freeing huge amounts of resources.
From the operations
perspective
For example, lean production frees
office and plant space and increases
capacity so companies can

 Add product lines

 In-source component production
 Increase output of existing products
without acquiring new facilities
KINERGARTEN OF ALL THE
QC TOOLS

5S IS THE STARTING POINT OF ALL

THE QC TOOLS

COULD BE SAID AS THE PRE-

REQUISITE OF ALL QC TOOLS
METHODOLOGY
OF 5S
1. ORGANISATION(SEIRI)
Decide what you need

Remove unnecessary clutter

All tools, gauges, materials, classified and then stored

Remove items which are broken, unusable or only

occasionally used
 RED
RED TAG TECHNIQUE TAG

• GIVE STAFF RED LABELS

• ASK STAFF TO GO THROUGH EVERY
ITEM IN THE WORK PLACE
• ASK IF NEEDED & THOSE THAT ARE
NEEDED,IN WHAT QUANTITY
• NOT NEEDED RED TAG IT
• STORE IN THE RED TAG AREA
 RED

For wavering items TAG

PLACE THE SUSPECTED ITEMS IN

THE RED TAG AREA FOR ONE WEEK
ALLOW THE STAFF TO REEVALUATE
THE NEEDED ITEMS
AT THE END OF WEEK THOSE WHO
NEED ITEMS SHOULD BE RETURNED
ORGANISATION
PRIORITY FREQUENCY OF USE HOW TO USE
Low Less than once Throw away
per year Store away
Once per year from the
workplace
Avg. Once per month Store
Once per week together but
offline
High Once Per Day Locate at the
workplace
2. ORDERLINESS(SEITON)

ONCE YOU HAVE ELIMINATED ALL

THE UNNEEDED ITEMS

NOW TURN TO THE LEFT OVER

ITEMS
ORDERLINESS(SEITON)

Organise layout of tools and

equipment
– Designated locations
– Use tapes and labels
– Ensure everything is available as it
is needed and at the “point of use”
ORDERLINESS(SEITON)
Workplace Checkpoints:-
Positions of aisles and storage places
clearly marked?
Tools classified and stored by frequency
of use?
Pallets stacked correctly?
Safety equipment easily accessible?
Floors in good condition?
3. SEISO (CLEAN/SHINE)

Create a spotless workplace

Identify and eliminate causes of dirt

and grime – remove the need to
clean

Sweep, dust, polish and paint

SEISO (CLEAN/SHINE)

Divide areas into zones

Define responsibilities for cleaning

Tools and equipment must be owned by an

individual

Focus on removing the need to clean

4. SEIKETSU
(STANDARDISE)
Generate a maintenance system for the first
three
Develop procedures, schedules, practices
Continue to assess the use and disposal of
items
Regularly audit using checklists and
measures of housekeeping
Real challenge is to keep it clean
5. SHITSUKE (SUSTAIN /
DISCIPLINE)
Means inoculate courtesy & good habits
Driving force behind all 5S
Deming’s point number 1: Constancy of
purpose
Make it a way of life
Part of health and safety
Involve the whole workforce*
Develop and keep good habits
LITMUS TEST FOR 5S

30 SECOND RULE

ONE MUST LOCATE THE ITEM WITH
IN 30 SECOND IF 5S IS PROPERLY
IMPLEMENTED
ALSO APPLIES TO THE ELECTRONIC
RECORDS RETRIEVAL
 WHAT CAN YOU
COME ACROSS
AT THE END OF DAY
Advantages of 5S

 NEAT & CLEAN WORKPLACE

 SMOOTH WORKING
 OBSTRUCTION FREE WORK SPACE
 INCREASED SAFETY
 IMPROVED PRODUCTIVITY
Continued…..

 IMPROVED QUALITY
 WASTAGE DECREASE
 MACHINE MAINTENANCE
 VISUAL CONTROL SYSTEM
 MOTIVATED EMPLOYEES
 WORKSTATIONS BECOMING
SPACIOUS